Method of adhering adhesive backed light reflector unit to a mounting surface



July 11, 1967 R. R. GUNDERSON 3,330,714

METHOD OF ADHERING ADHESIVE BACKED LIGHT REFLECTOR UNIT TO A MOUNTINGSURFACE Original Filed March 8, 1962 2 Sheets-Sheet 1 FIE.1

July 11, 1967 R. R. GUNDERSON 3,330,714

METHOD OF ADHERING ADHESIVE BACKED LIGHT REFLECTOR UNIT TO A MOUNTINGSURFACE. Original Filed March 8, 1962 2 Sheets-Sheet 2 F157 FIElUPRESSURE APPLIED 6 VACUUM 42 45 LET 1N AIR 40 41 4 PRESSURE z Li VACUUMAPPLIED United States Patent 3,330,714 METHGD 0F ADHERIN G ADHESIVEBACKED LIGHT REFLECTOR UNIT TO A MOUNTING SURFACE Ralph R. Gunderson,Vari-Products C0., 330 N. Harding, Chicago, II]. 60624 Originalapplication Mar. 8, 1962, Ser. No. 178,471, now Patent No. 3,266,371,dated Aug. 16, 1966. Divided and this application June 30, 1965, Ser.No. 468,472 6 Claims. (Ci. 156--286) This application is a division ofmy copending application Ser. No. 178,471, filed Mar. 8, 1962, andentitled Light Reflector Unit with an Undulatory Reflecting Insert, nowU.S. Patent No. 3,266,371 granted Aug. 16, 1966.

This invention relates to light reflectors having adhesive backings, andto a method for adhering such reflectors to a mounting surface.

The light reflectors of the present invention are widely employed aswarning reflectors for use in conjunction with vehicles traveling thehighways. Heretofore, such reflectors have been mounted in seats inmetal or plastic brackets which have in turn been secured to a vehiclemounting surface by cap screws or other mechanical means. Suchinstallations have failed to provide a hermetic seal so that thereflecting and refracting surfaces of the reflector become dirty duringuse; and in addition, the assembly and attachment of the reflectors hasbeen a timeconsuming endeavor.

The primary object of this invention is to provide a novel method forsecuring such adhesive back reflectors to a mounting surface.

Yet another object is to provide a novel method for exhausting air fromwithin a cavity of a reflective member when securing the reflectivemember to a mounting surface.

The invention is illustrative in a preferred embodiment in theaccompanying drawings, in which:

FIG. 1 is a top plan view of a light reflector unit showing a spacer orstop member in dotted outline;

FIG. 2 is a sectional view as indicated on line 2-2 of FIG. 1 showing acentral spacer element positioned between the adhesive backing and ametallic reflector insert within the cavity of the reflector andpositioned immediately beneath the light reflecting and refractingfacets of the inner face of the reflector unit;

FIG. 3 is a bottom plan view of a modified form of a reflector unithaving a gasket-type adhesive backing;

FIG. 4 is a sectional view taken as indicated on line 4-4 of FIG. 3;

FIG. 5 is a bottom plan view of a second modification of the reflectorunit showing an adhesive backing having a perforation near itsperiphery;

FIG. 6 is a sectional view taken on line 6-6 of FIG. 5;

FIGS. 7 through 11 illustrate diagrammatically the preferred method bywhich the above three embodiments of reflector units may be adhered to amounting surface;

FIG. 7 being a side elevational view of the preferred form of reflectorunit;

FIG. 8 being a diagrammatic sectional view showing the reflectorunitpositioned against the mounting surface with vacuum not yet appliedto the chamber of the illustrated tool;

FIG. 9 being a view similar to FIG. 8 illustrating the inner chamber ofthe tool being evacuated so that the internal pressure within the cavitywithin the reflector unit pushes outwardly upon the adhesive backing ofthe reflector unit in bellows-like fashion to press the central portionof the adhesive backing firmly against the mounting surface;

FIG. 10 being a view similar to FIG. 9 with the central chamber of thetool still exhausted and showing the application of a force to a movablemember within the chamber to apply pressure against the rim of thereflector unit forcing the entire face of the adhesive against themounting surface; and

FIG. 11 being a view similar to FIG. 10 but illustrating the release ofthe vacuum within the inner chamber of the tool perimtting air pressureto rush in and apply a compressive force to the entire exposed face ofthe reflector unit flattening the reflector unit and urging it radially;

FIG. 12 is an enlarged broken side elevational view partly in section ofthe reflector unit shown in FIG. 9, the view illlustrating the breakingaway of the adhesive back from the rim of the reflector unit to permitthe exhaust of air pressure from within the cavity of the reflectorunit; and

FIG. 13 is an enlarged broken side elevational view partly in section ofthe reflector of FIG. 11 to illustrate the deformation in the crown ofthe reflector unit by atmospheric pressure because of the exhaustedcondition of the hermetically sealed cavity within the reflector unit.

In the embodiment illustrated, and referring particularly to FIGS. 1through 3, a light reflector unit, generally designated 20, is shown.The unit 20 preferably includes an integral reflective member 21 formedfrom a lighttransmitting synthetic plastic. The material generally usedis methyl methacrylate commonly sold under the trade name Lucite. Thereflective member 21 includes a lightreceiving face 22 and a reverse orrear face 23 containing a plurality of retracting and reflectingprismatic surfaces 23a for receiving incoming light and causing saidlight to be redirected generally along its incoming path. The reflectivemember 21 may be circularly formed, and it is preferably provided with arearwardly extending annular wall 24 terminating in a peripheral rim orlip 25 which wall 24 and rim 25 afford an inner cavity 26.

As best shown in FIG. 2, it is preferred that an annular reflectinginsert 27 be positioned within the cavity 26 to receive and giveadditional reflection to incident light. The reflecting insert 27 ispreferably formed of aluminum foil and may have a ruflled forward facewhich when reflecting incident light provides a brightened or liveappearance to portions of the front face of the reflective member 21.The wrinkled appearance of the insert 27 is illustrated by the wavylines shown in the sectional view, FIG. 2.

A stop member 28 is also preferably placed within the cavity 26 betweena backing member 30 and the reflecting insert 27. As will besubsequently explained, the stop member 28 is generally a thickened slugof metal centrally disposed in the cavity 26 for the purpose of bearingbetween a mounting surface such as illustrated at 31 in FIG. 13 and therear face 23 of the reflective member 21. It will be noted in FIG. 2that there is a slight clearance between the insert 28 and the face 23but since the reflective member is resiliently deformable underpressure, the rear face 23 will be brought to bear upon the insert 23when the reflector unit is adhered to a mounting surface.

The backing member 30 is also best seen in FIG. 2. The backing member ispreferably formed of a thin plastic or of durable paper material whichis provided with a pressure-sensitive adhesive on each of its oppositefaces. Its inner face is adhered peripherally to the rim 25 of thereflective member 21. Its outer face prior to use is covered by aprotective paper material adhered in place by the pressure-sensitiveadhesive on the outer face. The adhesive on the inner face in this formof the invention has adhering qualities which cause it to be securedfirmly to the rim 25 of the reflective unit 21. Its adhering qualitiesare also of such nature as to permit the peripheral separation, that is,the adhesive will break away from the peripheral reflector rim when thedifferential between the air pressure within the cavity 26 and theambient air pressure about the reflector unit approximates 25" ofmercury.

A modification of another embodiment of a light reflector unit of thisinvention is illustrated in FIG. 3 and FIG. 4. The reflective member 21may be formed similarly to that shown in FIGS. 1 and 2. The chiefdifference in this modification is that a gasket-type backing member 32is provided which is again adhered on its inner face to the annular rim25. The outer face of the backing member 32, as shown in FIG. 3,provides a peripheral adherence of the backing member to a mountingsurface 31. The purpose of the annular or gasket-type backing member 32will be made more apparent on considering the method of adhering thistype of reflector unit to a mounting surface. However, briefly, theenlarged opening 33 in the backing member 32 plays a part in exhaustingthe inner cavity 26 of the reflective member 21 as the reflector unit isbeing adhered to a mounting surface.

Another embodiment of a reflector unit of this invention is shown inFIGS. 5 and 6. The structure of this embodiment may be formed in thesame manner as that in FIGS. 1 and 2. The 'only difference in structurelies in a perforated backing member 34. As shown in FIG. 5 and in FIG.6, the backing member is preferably provided with one or moreperforations 35 positioned near the periphery of the backing member 34and just inside the rim so as to communicate with the inner cavity 26.Again, the purpose of the perforations will be made more apparentsubsequently, in discussing the method of application of the reflectorunits, and it is sufiicient here to say that the perforation 35 plays apart in exhausting the inner cavity 26 of the reflector unit as thereflector unit is being adhered to the mounting surface.

It is contemplated in each of the three forms of the reflector unitshown in FIGS. 1 through 6 that the reflective members 21 and thebacking members 30, 32 and 34 may be formed and handled separately. Thatis, the reflecting members and their backing members may be packed andshipped separately by a manufacturer and then simply be assemblytogether as a unit at the time of adherence to a mounting surface. Thedouble-faced adhesive of the backing members 30, 32 and 34 (when packedseparately) is protected from adherence to other objects bypaper-covering material on each of its faces.

The unique method of adhering the reflector unit 20 shown in FIGS. 1 and2 to a mounting surface 31 is diagrammatically illustrated in FIGS. 7through 11. FIG. 7 illustrates the reflector unit 20 with the backingmember 30 adhered thereto and with the adhesive face of the backingmember 30 exposed.

FIG. 8 shows diagrammatically a type of tool for adhering the reflectorunit 20 to a mounting surface. The tool may include a vacuum bell orcup-shaped housing 36 which has a resilient annular seal 37 protrudingfrom the end of its side wall 38 to make an air-tight seal against amounting surface 31. The housing is provided with a bottom wall 40 whichmay be apertured at 41 to accommodate a vacuum hose 42 secured thereinand connected to a source of vacuum indicated generally at 43.

The bottom wall 40 may also be provided with a bushing 44 which makes asubstantially air-tight sliding fit about a shank 45. The end of theshank 45 may be secured to a cup-shaped plunger 46 adapted to make aclose sliding fit within the side walls 38. The plunger 46 preferablyhas an opening 47 which permits air to be pulled from within the vacuumbell 36 through the vacuum line 42 when desired to evacuate the housing36. A number of bleeder lines or passages 48 may be formed in theannular lip portion 50 of the plunger 46 for a purpose which willsubsequently be made more apparent.

When it is desired to adhere a reflector unit 20 to a mounting surface31, the unit 20 is first placed within the open end of the housing 36,as shown in FIG. 8, so that the annular rim 25 rests adjacent theannular lip portion 50 of the plunger 36. In practice, the reflectoradhering gun or tool is tipped so that the housing opens upwardly, andthe reflector unit 20 is simply dropped into place with the rim 25resting upon the lip portion 50. The housing 36 is, of course, shaped toaccommodate the particular shape of the reflector unit which is to beadhered. After the reflector unit 20 is dropped into place against thelip portion 48, a vacuum is applied (see FIG. 9) to exhaust air from theinterior of the housing 36 and plunger 46. The evacuation of the housing36 will cause the ambient air pressure to which the unit 20 is subjectedto hold the reflector unit 20 in firm contact against the lip portion50. This is true even though at this time the small bleeder lines 48 areopen to atmospheric pressure and are permitting air pressure to enter insmall quantities into the evacuated chamber within the housing 36.

In FIG. 9, the housing 36 has been pressed against a mounting surface 31so that the annular seal 37 provides an air-tight fit. As the interiorof the housing 36 continues to be exhausted under these conditions, thebleeder lines 48 also permit evacuation of the air pressure from betweenthe adhesive face of the reflector unit 20 and the exhausted face of themounting surface. Because of the great decrease in atmospheric pressurewithin the housing 36, the atmospheric pressure within the cavity 26 ofthe reflector unit 20 causes the flexible adhesive backing member 30 tobellow outwardly as at 51 so that the entire central portion of theflexible adhesive backing 30 is urged by the internal air pressurewithin the cavity 26 of the reflector unit 20 into firm and intimateadhering contact with the mounting surface 31.

In the practical application of this method, the interior of the housing36 is exhausted almost immediately so that the flexible backing member30 instantly bellows outwardly into adhering engagement with themounting surface 31. concomitantly therewith, or an instant of timelater, the internal air pressure within the cavity 26 of the reflectorunit 20 causes separation of a peripheral portion of the adhered backingmember 30 with the annular rim 25, the separation being indicated at 52in FIG. 12.

At this time, the cavity 26 of the reflector unit 20 and the entireinterior of the housing 36 is exhausted, or at least is at extremely lowair pressure. It has been found that the type of adhesive currently inuse on backing members 30 displays such adhering qualities with thenarrow Lucite rim 25 of the reflective member 21 that the adhesive willseparate, as at 52, when the pressure differential between the interiorof the reflector unit 20 and the interior of the housing 36 isapproximately 25" of mercury. This condition has been found to prevailwhen using reflecting members 21 approximately 3%" diameter and with acavity depth. Of course, the pressure differential required will varywith the flexibility of the backing member 30 and with the particularadhering qualities of the adhesive used. These factors may be readilyadjusted with any particular size of reflector unit with which thismethod is employed.

FIG. 10 illustrates the next step of the preferred method. It will berecalled that in FIG. 9 the backing member 30 is bellowed outwardlyagainst the mounting surface 31. Now in FIG. 10, a force is applied tothe handle 53 in the direction of the arrow to drive the shank 45 andthe plunger 46 downwardly against the annular rim 25. This movementreseals any separations 52 between the backing member 30 and the rim 25,and in addition, it causes the entire backing member to be urged intointimate contact with the mounting surface 31. It will be recalled thatthis sealing of the backing member 30 against the mounting surface 31 isbeing done in a vacuum so that practically no air pressure is trappedbetween the backing member 30 and the mounting surface 31 and atremendously effective seal is provided throughout the area of adherencebetween the backing member and the mounting surface.

FIG. 11 illustrates the next step of the preferred method. Immediatelyafter pushing the plunger 46 against the annular rim 25 of thereflective member 21, the vacuum line 42 is opened to the ambient airpressure. The inrushing air pressure strikes the entire front face 22 ofthe reflective member 21 a substantial blow and with substantial force.As stated earlier, the reflective member 21 is preferably resilientlydeformable, and the inrushing air pressure actually pushes the crown ofthe front face 22 from a position as indicated in FIGS. 7 and 10 to aposition as indicated in FIG. 11. In other words, the height of thecrown of the front face 22 is greatly diminished. This downward pressureupon the crown of the front face 22 causes a slight radial spreading ofthe reflective member 21.

It has been shown in practice that this sudden application of a force byair pressure and the deformation of the reflective member 21 upon itsadhering backing member 30 greatly improves the strength of adherence ofthe reflector unit to a mounting surface. The precise reason for theimprovement in the degree of adherence is not known. However, it isbelieved that the radial deformation of the reflective member 21 tendsto place the backing member 30 in tension, and in so doing, causes thebacking member 30 to be slightly moved into firmer and more intimatecontact with the mounting surface.

After forcing the reflector unit 20 down with the force of the airpressure (FIG. 11), the reflector gun or tool may be removed for asubsequent operation. The reflector unit 20 as finally adhered to amounting surface is shown in FIG. 13. It will be recalled that its innercavity 26 is now substantially exhausted of air pressure so that theentire exposed area of the reflective member 21 is being urged towardthe mounting surface 31 by a force of air pressure equal toapproximately 12 to 14 lbs. per square inch. Thus, even at altitudes of10,000 to 15,000 feet, the force of the air pressure is assisting andholding the reflector unit 20 in place. It is contemplated in thereflector unit shown in FIG. 13 that it may include a stop member 28such as is shown in FIG. 2 to control the amount of deformation impartedto the front face 22 of the reflective member 21.

Tests have been conducted which illustrate the highly successfuladherence of reflector units by utilizing the method of the presentinvention. For example, in one instance, a reflector unit was adhered toa sheet metal mounting surface by the method of this invention, and thereflector unit and the mounting surface were subjected to a temperaturecondition of -10 F. An eight pound weight was then dropped from a heightof three feet upon the back of the mounting surface opposite thereflector unit. The force of the blow of the eight pound weight caused adeformation in the sheet metal backing and in the body of the resilientreflector unit, but the adherence of the bond between the reflector unitand the sheet metal mounting surface remained completely intact.

A similar test was conducted under a temperature condition of 186 F.Again, the sheet metal surface and the reflector unit were deformed bythe force of the blow of the eight pound weight, but the reflector unitremained firmly adhered to its mounting surface.

The method described above can also be used with the reflector unitshown in FIGS. 3 and 4 which has the gasket-type backing member 32. Withthis type of backing member, and with the reflector unit being heldagainst the lip portion 50 of the plunger 46, it is contemplated thatthe inner cavity 26 of the reflector unit will be exhausted at the sametime as the interior of the housing 36. The access to the inner cavity26 is simply provided through the enlarged opening 33 of the gasket-typebacking member 32 which does not come down into firm engagement with amounting surface until pressure is applied by the plunger 36, as isillustrated in FIG. 10. Otherwise, the method with the reflector unithaving a gaskettype backing member 32 is the same as was previouslydescribed in relation to the unit for the backing member 30.

Reflector units utilizing perforated backing members 34 may also beadhered to a mounting surface by using the above disclosed method.Again, the only difference from the method described in respect to thebacking member 30 lies in the manner in which the inner cavity 26 of thereflector unit 20 is evacuated Since the backing member has a smallperforation 35 near its edge, the interior of the reflector unit 20 isexhausted through this perforation, then through the bleeder lines 48and finally through the vacuum line 42. Generally, the perforation issufliciently small so that the backing member 32 bellows outwardly intocontact with the mounting surface 31 by exhausting the interior of thehousing 36 as described above in relation to the backing member 30. Inall other respects, the adherence of a reflector unit 20 having aperforated backing member 34 is similar to that above described inrespect to reflector units having the backing member 30.

The foregoing detailed description is given for clearness ofunderstanding only and no unnecessary limitations are to be understoodtherefrom, as some modifications will be obvious to those skilled in theart.

I claim:

1. The method of adhering to a mounting surface a light reflector unithaving an inner cavity in its rear face, said method comprisingpositioning the reflector unit adjacent the mounting surface, placing anair-tight enclosure against the mounting surface and about the reflectorunit, exhausting air pressure from within the enclosure and from Withinthe cavity in the rear face of the reflector unit, and forcing thereflector unit against the mounting surface to adhere the rear face ofthe reflector unit to the mounting surface with the cavity beingsubstantially evacuated of air pressure.

2. The method of adhering to a mounting surface alight reflector unithaving a rim portion forming a rearwardly opening cavity and an adhesivebacking member covering said cavity and adhered to said rim, said methodcomprising positioning an exposed adhesive face of the backing memberadjacent the mounting surface, placing an air-tight enclosure about thereflector unit, exhausting air pressure from within the enclosure sothat the air un der pressure within the cavity of the reflector unitforces a portion of the adhesive backing member away from the rim of thereflector to permit air pressure to be exhausted from within the cavity,and forcing the reflector unit and its adhesive backing member againstthe mounting surface to re-adhere the backing member to the rim of thereflector unit and to adhere the exposed adhesive face of the backingmember to the mounting surface and thereby to retain the cavitysubstantially evacuated of air pressure.

3. The method of adhering to a mounting surface a light reflector unithaving an inner cavity opening rearwardly of the unit, said methodcomprising positioning the front face of the reflector unit against stopmeans within a vacuum chamber housing so that the ambient air pressureholds the unit against the stop means, positioning the housing against amounting surface so that the housing forms with the mounting surface anair tight enclosure about the reflector unit, exhausting air pressurefrom within the enclosure and from within the cavity in the reflectorunit, and forcing the reflector unit against the mounting surface toadhere the rear face of the reflector unit to the mounting surface.

4. The method of adhering to a mounting surface a light reflector unithaving a cavity in its rear face, said method comprising positioning thelight reflector unit adjacent the mounting surface, placing an air tightenclosure about the reflector unit, exhausting the air from within theenclosure about the reflector unit and from the cavity in the reflectorunit, forcing the reflector unit against the mounting surface to adherethe reflector unit to said surface, and admitting air at the ambientpressure into the enclosure and against the reflector unit to secure thereflector unit to the mounting surface under the action of such ambientair pressure.

5. The method of adhering to a mounting surface a light reflector unithaving a cavity in its rear face and an adhesive backing memberreleasably secured to the rear face of said reflector unit and coveringsaid cavity to confine air in said cavity, said method comprisingpositioning the adhesive face of the backing member of the lightreflector unit adjacent to the mounting surface, placing an air-tightenclosure about the reflector unit and against the mounting surface,exhausting the air from within the enclosure and from between theadhesive backing member of the mounting surface and to release thebacking member from the rear face of the reflector unit whereby toexhaust the air from the cavity in the reflector unit, forcing thereflector unit against the mounting surface to adhere the adhesivebacking member to said surface, and admitting air at the ambientpressure into the enclosure and against the reflector unit to press thereflector unit and the backing member against the mounting surface.

6. The method of adhering to a mounting surface a light reflector unithaving an internal cavity opening in the rear face of the unit and aflexible adhesive backing member releasably secured to said rear faceand closing said cavity, said method comprising positioning the adhesiveface of the flexible backing member of the reflector unit adjacent tothe mounting surface, placing an air tight enclosure about the reflectorunit, exhausting the air pressure from the enclosure to permit the airwithin the cavity of the reflector unit to force the flexible backingmember to bellow outwardly into adhering contact with the mountingsurface and into cavity opening position to release the air within saidcavity, forcing the reflector unit against the mounting surface toflatten the backing member into complete adhering contact with themounting surface and into cavity closing position, and admitting airunder ambient pressure into the exhausted enclosure and against thefront face of the light reflector unit to secure said unit to themounting surface under the action of such ambient air pressure.

References Cited UNITED STATES PATENTS 711,212 10/1902 Honiss 531032,184,824 12/1939 Von HOfG 156-285 2,657,847 11/1953 Heitmann 53-103 X2,690,593 10/1954 Abercombie 531 12 2,968,460 1/1961 Van Dusen 2482063,134,208 5/1964 RiChIIlOIld 26921 X 3,224,106 12/1965 Way 26921 X3,282,763 11/1966 GUndfiISOIl 156382 X EARL M. BERGERT, PrimaryExaminer.

HAROLD ANSHER, Examiner.

1. THE METHOD OF ADHERING TO A MOUNTING SURFACE A LIGHT REFLECTOR UNITHAVING AN INNER CAVITY IN ITS REAR FACE, SAID METHOD COMPRISINGPOSITIONING THE REFLECTOR UNIT ADJACENT THE MOUNTING SURFACE, PLACING ANAIR-TIGHT ENCLOSURE AGAINST THE MOUNTING SURFACE AND ABOUT THE REFLECTORUNIT, EXHAUSTING AIR PRESSURE FROM WITHIN THE ENCLOSURRE AND FROM WITHINTHE CAVITY IN THE REAR FACE OF THE REFLECTOR UNIT, AND FORCING THEREFLECTOR UNIT AGAINST THE MOUNTING SURFACE TO ADHERE THE REAR FACE OFTHE REFLECTOR UNIT TO THE MOUNTING SURFACE WITH THE CAVITY BEINGSUBSTANTIALLY EVACUATED OF AIR PRESSURE.